Mold and Process for Combining Metal/Ceramic and Polymer Component Mixture in the Formation of Homogenous Parts and Further Including an Article of Manufacture and Process for Creating a Combination Plastic and Silver Composite Exhibiting Lifelong Anti-Biotic PropertiesMold and Process for Combining Metal/Ceramic and Polymer Component Mixture in the Formation of Homogenous Parts and Further Including an Article of Manufacture and Process for Creating a Combination Plastic and Silver Composite

ABSTRACT

The present invention discloses a composite structural article exhibiting a three dimensional shape and size and including an admixture including at least one of a metal and a ceramic component, this combined with at least one polymeric component. In a further revised application, the article can include an admixture including at least one of a silver and a polymeric component.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 12/422,334 filed Apr. 13, 2009, which in turn claims thebenefit of both U.S. Provisional Application 61/044,169 filed on Apr.11, 2008 and U.S. Provisional Application 61/112,978 filed on Nov. 10,2008.

FIELD OF THE INVENTION

The present invention relates to molds, assemblies and techniques forintermixing metals and/or ceramics in grounded, beaded or powderizedform with a thermoplastic or thermosetting polymer in a likewise powder,liquid or micro-pellet form, this in order to produce a composite partexhibiting a homogeneous composition. Additionally, the presentinvention relates to molds, assemblies and techniques for intermixingfirst and second materials, such as polymers and metals. In one specificapplication, the present invention discloses an article of manufactureand process for creating a combination and homogeneously mixed plasticand silver composite exhibiting lifelong anti-biotic properties.

BACKGROUND OF THE INVENTION

The prior art is documented with examples of forming or mixing togethermaterials having distinct properties or characteristics into a compositeadmixture. A problem associated with combining together such materials,in particular when those materials exhibit different or uniquecharacteristics, is the inability of such admixtures to achievesufficient uniformity or homogeneousness.

SUMMARY OF THE INVENTION

The present invention discloses a composite structural articleexhibiting a three dimensional shape and size and which includes anadmixture of at least one of a metal and a ceramic component, combinedwith at least one polymeric component. The metal and/or ceramiccomponent can further be provided according to at least one of agrounded, beaded, or powder form, whereas the polymeric component canfurther be provided according to at least one of a powder, micro-pelletor liquid form. The polymeric component may also include any of athermoplastic and/or a thermosetting component, and further includingsuch as a composite admixture of the two.

In one preferred application, a multiple metal/ceramic and polymericcomponent is admixed together into a composite matrix. The metallicand/or ceramic components can include any of a Beryllium, Boron, Brass,Bronze, Chromium, Cobalt, Copper, Dysprosium, Hafnium, Iridium, Iron,Lutetium, Manganese, Molybdenum, Neodymium, Nickel, Niobium, Palladium,Rhodium, Silicon, Tantalum, Technetium, Titanium and Zirconium.

The polymeric component can also include any of an ABS 301, ASA Centrex811 Black, Acetyl Celcon M270, C-Flex TPE Compound, Delrin, Dow Magnum,Dow Pellethane, Dylark EQ PSA, Micholac D2850 Black, Nylon 13% GF, Nylon2010 (nylon 6) Natural, OIPEKK-C, PolyProBlack, Polytrope TPP517-2274Dark Umber, PP Natural, Pulse, Ultem, Valox 325, Xenoy 1760 Black EQ,and Zytel.

A related composite structural article exhibits an admixture includingat least one of a silver and a polymeric component. The silver isprovided according to at least one of a granulate or a particulate formand which is intermixed within a three dimensional polymeric matrix.

The polymeric component can further be provided according to at leastone of a powder, micro-pellet or liquid form and prior to combining withthe silver within a mold. The polymeric component can further include atleast one of a thermoplastic and a thermosetting component. Thepolymeric component further includes at least one of an ABS 301, ASACentrex 811 Black, Acetyl Celcon M270, C-Flex TPE Compound, Delrin, DowMagnum, Dow Pellethane, Dylark EQ PSA, Micholac D2850 Black, Nylon 13%GF, Nylon 2010 (nylon 6) Natural, OIPEKK-C, PolyProBlack, PolytropeTPP517-2274 Dark Umber, PP Natural, Pulse, Ultem, Valox 325, Xenoy 1760Black EQ, and Zytel.

At least one additional metal/ceramic and polymeric component is admixedtogether with the silver into a composite matrix. The metallic and/orceramic components can include at least one of a Beryllium, Boron,Brass, Bronze, Chromium, Cobalt, Copper, Dysprosium, Hafnium, Iridium,Iron, Lutetium, Manganese, Molybdenum, Neodymium, Nickel, Niobium,Palladium, Rhodium, Silicon, Tantalum, Technetium, Titanium andZirconium.

In an additional sub-variant, the silver component includes at least onesheet arranged in interspersed and spaced apart fashion relative to athree dimensional polymeric matrix. This can further include a top andbottom surface sheets, containing therebetween the polymeric matrix. Thesheets may further exhibit undercut portions for engaging within thepolymeric matrix. Alternatively, the sheet can possess a wave likeprofile.

The present invention also includes a mold assembly for use in producinga composite structural article, this including an upper assembleablehalf and an opposing and lower assembleable half, these collectivelydefining therebetween an interior cavity corresponding in enclosed threedimensional configuration to the article. Respective locating guiderecesses and inserting pins are established between mating surfaces ofthe mold halves and which, upon locating and securing the mold halvestogether, additionally receiving insert fasteners to secure the moldhalves together. Insert fasteners engage through interiorly threadedmounting holes which are aligned between the mold halves, such as uponthe pins and recesses seating relative to one another. A gyroscopic(i.e. multi-axially rotating) cage is provided supporting the mold forrotation about first and second rotational axes.

A related mold process creates the composite structural article andincludes the steps of heating a mold tool exhibiting an interiorly andthree dimensional defining cavity to a desired elevated temperature,premixing a desired percentage of at least one of metal and a ceramiccomponent, following which a desired component of a polymeric materialis added. Additional steps include depositing the composite mixture ofingredients, such as by emptying or pouring, into the open cavity,closing the mold such that the cavity is sealed, rotating the closedmold about multiple axes and such that centrifugal forces generated inturn cause the admixed components to evenly distribute, and coolingprior to removal of a completed part.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the attached drawings, when read incombination with the following detailed description, wherein likereference numerals refer to like parts throughout the several views, andin which:

FIG. 1 is an itemized listing of metal/ceramic and polymer componentsincorporated into the composite part mold and process;

FIG. 2 is a side cutaway of an assembleable mold for producing acomposite part;

FIG. 3 is a perspective view of an assembled mold, prefilled with avolume of composite mix, and concurrently rotated about first and secondperpendicular axes;

FIG. 4 is a sample illustration of a composite part formed by theprocess according to the present inventions; and

FIGS. 5 a-5 e are a series of cutaway plan view illustrations of variousthree dimensional articles which are created by combining or admixing asilver material, such as in varying sheet or granulate form, incooperation with any of a powderized, fluidized or three dimensionallyformed plastic, and in order to create a long term (lifelong)anti-biotic material.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the present illustrations, a series of molds, assembliesand techniques are disclosed for intermixing metals and/or ceramics ingrounded, beaded or powderized form with a thermoplastic orthermosetting polymer in a likewise powder, liquid or micro-pellet form.This is accomplished in order to produce a composite part exhibiting ahomogeneous composition and which can function in a variety of differentstructural applications.

Referring first to FIG. 1, an itemized listing is provided ofmetal/ceramic, as well as polymer components incorporated into thecomposite part mold and process. In particular, the present inventioncontemplates the combining of metal and/or ceramic with any type ofplastic (with varying percentage ranges) which, in cooperation with theassociated mold processes and techniques, create generally homogeneouslyappearing and three dimensional articles.

While not intended to be complete or exhaustive listing according to anymeasure, an incomplete listing of metal/ceramic components can includeone or more of: Beryllium, Boron, Brass, Bronze, Chromium, Cobalt,Copper, Dysprosium, Hafnium, Iridium, Iron, Lutetium, Manganese,Molybdenum, Neodymium, Nickel, Niobium, Palladium, Rhodium, Silicon,Tantalum, Technetium, Titanium and Zirconium.

Associated polymer or plastic based components can likewise include(according to a non-exhaustive listing), such as: ABS 301, ASA Centrex811 Black, Acetyl Celcon M270, C-Flex TPE Compound, Delrin, Dow Magnum,Dow Pellethane, Dylark EQ PSA, Micholac D2850 Black, Nylon 13% GF, Nylon2010 (nylon 6) Natural, OIPEKK-C, PolyProBlack, Polytrope TPP517-2274Dark Umber, PP Natural, Pulse, Ultem, Valox 325, Xenoy 1760 Black EQ,and Zytel.

All other metals/ceramics can also be inter-mixed with thermosetting (orthermoplastic) materials. The polymer and thermosetting materials canalso be mixed with the metal and plastics according to any relativepercentage range (by either weight or volume) ranging from 1%-99% perrespective components, and in order to create an eventual molded partexhibiting a set of properties associated with a desired application.

As previously described, the manner and consistency of incorporate eachmetal/ceramic and polymeric (thermoplastic or thermosetting) materialsis subject to any desired variance, again which can include themetal/ceramic applied in any one or more of ground, bead or powdermaterials, exhibiting any desired diameter or granular/particulate size.Correspondingly, the polymer materials can be introduced in any one ormore of a powder, micro-pellet and/or liquid form, and in order toachieve the desired evenly mixed (homogeneous) composition associatedwith the eventual 3D article produced by the associated mold process.

Referring now to FIG. 2, a side cutaway illustration is generally shownat 10 of an assembleable mold for producing a composite part. The moldincludes an upper assembleable half 12 and an opposing and lowerassembleable half 14, these defining therebetween an interior cavitycorresponding in enclosed three dimensional configuration to an eventualcomposite/homogenized part, see further as representatively shown at 18in FIG. 4) which is produced according to the present invention.

As further illustrated, the mold halves 12 and 14 include respectivelocating guide recesses 20 & 22 and inserting pins 24 & 26 establishedbetween mating surfaces and which, upon locating and securing the moldhalves together, additionally receive inserting fasteners or mountingbolts 28 & 30, these seating and threadably engaging respectively withassociated and interiorly threaded mounting holes 32 (in mold half 12)as well as at 34 (in mold half 14), these being aligned upon mating ofthe mold halves, and upon the pins and recesses seating relative to oneanother. Additional features shown in FIG. 2 include the provision of afirst pair 36 & 38 of axis defining and rotating support locations,these cooperating with a surrounding cage of desired configuration (seeelements 40, 42, 44 and 46 in FIG. 3) and such that the enclosed (andpre-filled mold) is capable of being rotated about a first axis 46(again FIG. 3) in cooperation and simultaneously with being rotatedabout a second axis 48 and according to a generally gyroscopic fashion.

As further understood, and although not generally shown, a gyroscopiclike apparatus typically consists of a rotating wheel so mounted thatits axis can turn freely in certain or all directions, and which iscapable of maintaining the same absolute direction in space in spite ofmovements of the mountings and surrounding parts, these again being usedto maintain equilibrium, determine direction, etc. That said, thepresent invention does not provide a more comprehensive depiction of agyroscopic-like apparatus for supporting and rotating the enclosed moldin multi-axial and selective rotational speeds, it being understood thatsuch technology is available and which is incorporated into theteachings of the present inventions.

A brief operating protocol will now be described in reference to themixing, filling, rotating and completing the process of creating a threedimensional homogenously evenly mixed and distributed composite partaccording to the present inventions. It is further again understood thatthe protocol described below accounts for only one possibleconfiguration for producing the composite part according to the presentinventions.

As a first step, the mold tool is heated such that the interiorly andthree dimensional defining cavity achieves a desired elevatedtemperature (in one non-limiting variant approximately 400° F.).Reference is also made to conductive heating channels as shown at 50 and52 in reference to the upper and lower mold halves in FIG. 1, thesecommunicating an external electrical resistance or other suitableheating medium (not shown) with the generally metallic construction ofthe mold defining cavity.

A second step contemplates premixing of the materials, such as accordingto any desired fashion and by which an initial degree of homogeneity isestablished between the composite materials which respectively exhibitany of a fluidic/granular/aggregate consistency. The admixed materialsmay further exhibit any desired percentage (by volume or weight) of anytype of suitable metal and/or ceramic component, following which adesired component of polymeric material is added.

In a third step, and following the pre-mixing of all ingredients, themixture is emptied or deposited, such as by pouring, into the opencavity. At this point, the top mold half is aligned and fastened overthe bottom mold half. This is typically accomplished with the assistanceof hydraulic or mechanical actuators, and given the relative weight ofthe mold and composite ingredients.

After being secured, mounted and deployed within the gyroscopic stylecarriage assembly, the enclosed and pre-filled mold is rotated about itsmultiple axis, see as shown again in FIG. 3, and such that thecentrifugal forces generated cause the components to evenly distribute(or to further intermix beyond an initially admixed stage). In aspecific further desired application, the composite admixture ofmaterials is caused to gravitate towards outer peripheral locationsassociated with the composite product thereby produced. The employmentof modified centrifugal forces is also desired, again in such particularinstances, in the production of an article exhibiting some degree of ahollow interior. Additional aspects of the rotating step include themold being multi-axially rotated at varying speeds and time intervals.

Following completion of the multi-axial rotation cycle, the tool issubjected to cooling (such as by communicated water, cooling air or thelike which is not shown but which is well understood to be within theordinary skill of one in the art to do). The time frame associated withthe cooling cycle can vary however, and in a most extreme instance, canbe accomplished in as little as 1-10 seconds. In this fashion, use of aliquid based coolant (e.g. water, glycol solution or the like) can bemanipulated such that it does not directly contact the mold cavity, butrather will cool the adjoining surface of the tool, thereby cooling themetal from its elevated temperature (e.g. again 450° F. to a saferrelease temperature of 100° F.).

In the final step, the cavity is reopened and the finished compositepart removed. The mold process employed herein functions to produce ahomogenous part exhibiting vastly increased and improved surfaceproperties, and which further makes possible the utilization of a widervariety of metallic/ceramic/polymeric components given again 1) theability to provide intermixed ratios of one or more of these componentsaccording to any relative percentages by volume or weight and 2) theprovision of the components in a desired granulate, micro-pellet orliquid form, and such that the desired end product exhibits theseintermixed or entrained components according to a fused and hardenedeven admixture.

Referring finally to FIGS. 5 a-5 e, the present discloses a series ofcutaway plan views of molds, assemblies and techniques are disclosed forintermixing a silver and a (polymeric) plastic material. The use ofsilver combined with plastics can include providing either or bothmaterials in such as a grounded, beaded, sheet or other 3D form,powderized, micro-pellet or liquid form and in order to create anarticle exhibiting desired (lifelong) anti-biotic properties. Such acombined article can function as a material matrix for creating medicalimplements or other structural articles for which sanitary or infectiousissues are at play.

By nature, silver is a very ductile and malleable metal exhibiting abrilliant white metallic luster that can take a high degree of polish.It has the highest electrical conductivity of all metals, even higherthan. Further, among metals, pure silver has the highest thermalconductivity, as well as among the highest optical reflectivity. Silveralso has the lowest contact resistance of any metal. Silver is stable inpure air and water, but tarnishes when it is exposed to air or watercontaining ozone or hydrogen sulfide.

As is also known, silver ions and silver compounds show a toxic effecton some bacteria, viruses, algae and fungi, typical for heavy metalslike lead or mercury, but without the high toxicity to humans that isnormally associated with these other metals. Its germicidal effects killmany microbial organisms in vitro (in an artificial environment outsidethe living organism). Silver's germicidal effects increase its value inutensils and as jewelry. Silver compounds were used to prevent infectionin up to the early 1900's and before the advent of antibiotics. Silvernitrate solution was a standard of care but was largely replaced bysilver sulfadiazine cream (SSD Cream), which was generally the “standardof care” for the antibacterial and antibiotic treatment of serious burnsuntil the late 1990s.

More recently, there has been renewed interest in silver as abroad-spectrum antimicrobial material. In particular, silver is beingused with alginate, a naturally occurring biopolymer derived fromseaweed, in a range of products designed to prevent infections as partof wound management procedures, particularly applicable to burn victims.

The present invention seeks to combine (such as through any moldforming, casting, extrusion or admixing process) a plasticized materialwith silver. Each component is provided in a complementary percentage(1-99%) relative to the other, this in order to create a desiredstructural article. This is accomplished in order to produce a compositepart exhibiting a homogeneous composition and which can function in avariety of different structural applications.

Prior to referring to each of the structural applications shown in FIGS.5 a-5 e, an itemized listing is provided of associated polymer orplastic based components can likewise include (according to anon-exhaustive listing), such as: ABS 301, ASA Centrex 811 Black, AcetylCelcon M270, C-Flex TPE Compound, Delrin, Dow Magnum, Dow Pellethane,Dylark EQ PSA, Micholac D2850 Black, Nylon 13% GF, Nylon 2010 (nylon 6)Natural, OIPEKK-C, PolyProBlack, Polytrope TPP517-2274 Dark Umber, PPNatural, Pulse, Ultem, Valox 325, Xenoy 1760 Black EQ, and Zytel.

As previously stated, the silver material (regardless of liquid, solidor powderized form) can be combined, inter-mixed or admixed withthermosetting (or thermoplastic) materials. The polymer andthermosetting materials can again be mixed with the silver according toany relative percentage range (by either weight or volume) ranging from1%-99% per respective components, and in order to create an eventual(such as molded) part exhibiting a set of properties associated with adesired application.

Referring first to FIG. 5 a, an illustration is shown at 54 (such as inplan cutaway) of a three dimensional article exhibiting a silverparticulate (minority percentage) material 56 intermixed within aplastic (majority percentage) matrix 58. While not shown, the article 54can be produced such as within a closed mold process (exhibiting acombined heat and pressure), or can be created utilizing extruding orother process forming operations, and by which the silver is provided asa particulate/granulate which is evenly dispersed or distributedthroughout the plastic matrix.

FIG. 5 b illustrates, at 60, a variation of a three dimensional article,and by which the silver component is provided as a plurality ofindividual and spaced apart sheets 62. In one practical manufacturingprocess, the silver sheets 62 are pre-arranged or positioned within aclosed mold, within which is then injected a plastic matrix 64 to createthe desired finished article.

Referring to FIG. 5 c, illustrated at 66 is a modification of the threedimensional article as generally shown in FIG. 5 b and in particular inwhich the granulate silver component 68, while interspersed throughoutthe plasticized matrix 70, is congregated in greater percentages towardsthe outer (upper and lower) surfaces of the three dimensional articlecreated. In this fashion, the article created can exhibit a maximizedantibiotic effect while effectively managing a (minority) percentage ofsilver intermixed within the plastic matrix.

FIG. 5 d illustrates at 72 a further plan cutaway of a 3D article and inwhich a pair of silver sheets 74 are applied to upper and lowersurfaces, and between which is formed an interior composed of a plasticmatrix 76. As shown, the top and bottom surface applied silver sheets 74can each exhibit inner extending prongs or undercut portions, at 78,these providing additional gripping force when secured with the plasticmatrix interior (such as again during a mold or other suitable formationprocess). Furthermore, the matrix 76 interior can exhibit either anabsence, or a smaller percentage, of silver particulate depending uponthe antibiotic requirements and application of the desired article.

Finally, FIG. 5 e illustrates, at 80, a series of undulating, wafer likesheets, see at 82 and 84, which are provided in pairs at both top andbottom surface locations of the matrix material, see further at 86. Thesilver sheets 82 and 84 further exhibit individual undercut portions,with additional sheets 88 and 90 representing a top surface of thematrix and exhibiting a smooth, wavy-like profile.

Having described my invention, other and additional preferredembodiments will become apparent to those skilled in the art to which itpertains, and without deviating from the scope of the appended claims.This can include the three dimensional article also exhibiting a thirdcomponent, drawn from any type of additional metal and/or ceramicmaterial and such as which may include Beryllium, Boron, Brass, Bronze,Chromium, Cobalt, Copper, Dysprosium, Hafnium, Iridium, Iron, Lutetium,Manganese, Molybdenum, Neodymium, Nickel, Niobium, Palladium, Rhodium,Silicon, Tantalum, Technetium, Titanium and Zirconium. It is alsoenvisioned and understood that other aggregate or filler components canbe incorporated into the three dimensional matrix.

Having described my invention, other and additional preferredembodiments will become apparent to those skilled in the art to which itpertains, and without deviating from the scope of the appended claims.

1. A mold process for creating a composite structural article,comprising the steps of: heating a mold tool exhibiting an interiorlyand three dimensional defining cavity to a desired elevated temperature;premixing a desired percentage of at least one of metal and a ceramiccomponent, following which a desired component of a polymeric materialis added; depositing said composite mixture of ingredients, such as byemptying or pouring, into the open cavity; closing the mold such thatsaid cavity is sealed; rotating said closed mold about multiple axes andsuch that centrifugal forces generated in turn cause said admixedcomponents to evenly distribute; and cooling prior to removal of acompleted part.
 2. The mold process according to claim 1, furthercomprising the step of premixing said metal, ceramic and polymericcomponents in at least one of a grounded, beaded, powderized, pellet orliquid form.
 3. The mold process according to claim 1, furthercomprising the step of pre-mixing multiple metal/ceramic premixes andpolymeric components into a composite matrix.
 4. The mold processaccording to claim 1, said step of adding a polymeric material furthercomprising adding at least one of a thermoplastic and a thermosettingmaterial.
 5. The mold process according to claim 1, further comprisingthe step of providing said mold as an upper half and a lowerassembleable half.
 6. The mold process according to claim 5, furthercomprising the step of locating male and female features associated withopposing surfaces of said upper and lower assembleable mold halves. 7.The mold process according to claim 1, said step of rotating said closedmold about multiple axes further comprising mounting said mold within agyroscopic cage.